Bracket for Connection of a Junction Box to Photovoltaic Panels

ABSTRACT

A device for attaching a junction box to a photovoltaic. The photovoltaic panel has a photovoltaic side and a non-photovoltaic side. The device includes a bracket with a first side attachable to the junction box and a second side attachable to the non-photovoltaic surface of the photovoltaic panel. A central fastener is attachable at one end to the bracket and a plate is adapted for connecting to the other end of the central fastener and for mounting on the photovoltaic side of the photovoltaic panel. One or more rotatable spacers, connectible to the central fastener, may be located on the non-photovoltaic side of the photovoltaic panel. One or more fixed spacers may be located on the non-photovoltaic side connectible to the bracket.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit from U.S. patent application 61/180,912filed May 25, 2009, the disclosure of which is incorporated herein byreference.

BACKGROUND 1. Technical Field

The present invention relates to attaching junction boxes tophotovoltaic panels and specifically to a bracket for attaching junctionboxes to photovoltaic panels.

2. Description of Related Art

A photovoltaic module or photovoltaic panel is a packaged interconnectedassembly of photovoltaic cells, also known as solar cells. Since asingle photovoltaic module can only produce a limited amount of power,commercial installations include several modules or panelsinterconnected in serial and in parallel into a photovoltaic array.Electrical connections are made in series to achieve a desired outputvoltage and/or in parallel to provide a desired amount of current sourcecapability. A photovoltaic installation typically includes the array ofphotovoltaic modules, an inverter, batteries and interconnection wiring.Electronic modules may be integrated with the photovoltaic modules whichperform electrical conversion, e.g. direct current (DC) to directcurrent conversion, electrical inversion, e.g. micro-inverter, or otherfunctions such as monitoring of performance and/or protection againsttheft.

An approach for mounting photovoltaic modules on the roofs of buildingsis disclosed in U.S. Pat. No. 7,435,897, which discloses attaching ajunction box to a bracket as part of a photovoltaic installation.

The term “cable gland” as used herein refers to a device used for theentry of electrical cables or cords into electrical equipment and isused to firmly secure an electrical cable entering a piece of electricalequipment.

The terms “bracket”, “mount” and “bracket mount” are used hereininterchangeably.

The terms “central fastener” and “central pillar” are used hereininterchangeably.

BRIEF SUMMARY

According to an aspect of the present invention there is provided adevice for attaching a junction box to a photovoltaic panel, thephotovoltaic panel having a photovoltaic side and a non-photovoltaicside. The device includes a bracket with a first side attachable to thejunction box and a second side attachable to the non-photovoltaicsurface of the photovoltaic panel. A central fastener is attachable atone end to the bracket and a plate is adapted for connecting to theother end of the central fastener and for mounting on the photovoltaicpanel or frame typically on the photovoltaic side of the panel. One ormore rotatable spacers, connectible to the central fastener, may belocated on the non-photovoltaic side of the photovoltaic panel. One ormore fixed spacers may be located on the non-photovoltaic sideconnectible to the bracket.

The bracket may attach to respective non-photovoltaic sides of twoadjacent photovoltaic panels and the central fastener extends betweenrespective edges of the two adjacent photovoltaic panels. The twoadjacent panels are electrically connectible within the junction box.The bracket may also attach to respective non-photovoltaic sides of fouradjacent photovoltaic panels, with the central fastener extendingbetween respective corners of the four adjacent photovoltaic panels. Thefour adjacent panels are typically connected electrically within thejunction box.

According to another aspect of the present invention, there is provideda method for attaching a junction box to one or more photovoltaicpanels. The photovoltaic panel has a photovoltaic side and anon-photovoltaic side. A first side of a bracket is attached to thejunction box and a second side of the bracket is attached to thenon-photovoltaic side. A central fastener is attached at one end to thebracket. A plate usually rotatable is connected to the other end of thecentral fastener and mounted on the photovoltaic side of thephotovoltaic panel. One or more spacers are optionally rotatable andconnected on the non-photovoltaic side to the central fastener. Thebracket may be attached to non-photovoltaic sides of two adjacentphotovoltaic panels and the central fastener extends between respectiveedges of two adjacent photovoltaic panels. The two adjacent photovoltaicpanels may be electrically connected within the junction box.Alternatively, the bracket is attached to non-photovoltaic sides of fouradjacent photovoltaic panels, and the central fastener extends betweenrespective corners of the four adjacent photovoltaic panels. The fouradjacent photovoltaic panels may be connected within the junction box.

These, additional, and/or other aspects and/or advantages of the presentinvention are: set forth in the detailed description which follows;possibly inferable from the detailed description; and/or learnable bypractice of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, withreference to the accompanying drawings, wherein:

FIG. 1a shows a junction box mechanically attached to two photovoltaicpanels by a bracket according to an aspect of the present invention.

FIG. 1b shows two junction boxes, which may be mounted (using a bracket)in various positions on multiple panels, according to an aspect of thepresent invention.

FIG. 1c shows a topside plan view of a bracket mount according to anaspect of the present invention.

FIG. 1d shows a side view of a bracket mount according to an aspect ofthe present invention.

FIG. 1e shows a bottom side plan view of a bracket mount according to anaspect of the present invention.

FIG. 1f shows an isometric view looking at the topside of a bracketmount according to an aspect of the present invention.

FIG. 1g shows an isometric view looking at the bottom side of a bracketmount according to an aspect of the present invention.

FIG. 2a shows a topside plan view of a bracket mount mounted to ajunction box according to an aspect of the present invention.

FIG. 2b shows a side view of a bracket mount mounted to a junction boxaccording to an aspect of the present invention.

FIG. 3a shows the photovoltaic side of two solar panels with a bracketmount and a junction box attached in between the two solar panelsaccording to an aspect of the present invention.

FIG. 3b shows further details of a bracket mount and a junction boxattached in between two solar panels according to an aspect of thepresent invention.

FIG. 4 shows a flow diagram illustrating a method according to featuresof the present invention for attaching a junction box to one or morephotovoltaic panels.

The foregoing and/or other aspects will become apparent from thefollowing detailed description when considered in conjunction with theaccompanying drawing figures.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings, wherein like reference numerals refer to the like elementsthroughout. The aspects are described below to explain the presentinvention by referring to the figures.

Before explaining aspects of the invention in detail, it is to beunderstood that the invention is not limited in its application to thedetails of design and the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other aspects or of being practiced or carried out in variousways. Also, it is to be understood that the phraseology and terminologyemployed herein is for the purpose of description and should not beregarded as limiting.

Reference is now made to FIG. 1a which shows a junction box 200mechanically attached to two photovoltaic panels 300 b and 300 arespectively by a bracket 10 according to an aspect of the presentinvention. Junction box 200 is typically mounted on the non photovoltaicsides of panels 300 a and 300 b. Junction box 200 may typically containa circuit board and connection terminals which are both used toterminate cables entering and leaving junction box 200 using cableglands 14, male socket connectors 12 a and female socket connectors 12b. Junction box 200 typically provides a way for connecting panels 300 aand 300 b electrically together. The junction box may be passiveincluding connector and wires, and possibly passive elements such asdiodes, or active—e.g. containing a circuit board inside that implementsa direct current (DC) to alternating current (AC) inverter or a DC to DCconverter. Junction box 200 is attached to a bracket or mount 10 andbracket 10 is used to attach junction box 200 to photovoltaic panels 300a and 300 b.

Reference is now made to FIG. 1b which shows junction boxes 200 a and200 b, which may be mounted (using bracket 10) in various positions onmultiple panels 300 a, 300 b, 300 c or 300 d, according to an aspect ofthe present invention. Junction box 200 a may be used to connect panels300 a and 300 b electrically together. Alternatively, junction box 200 bshown located near cross point 666 or at cross point 666 of panels 300may be used to connect panels 300 a, 300 b, 300 c or 300 d electricallytogether.

Reference is now made to FIGS. 1c, 1d and 1e which show top side planview, a side view and a bottom side plan view respectively of a bracketmount 10 according to an aspect of the present invention. Bracket mount10 has a four mounting holes 102 used to secure bracket mount 10 tojunction box 200. Bracket 10 also has two fixed positioned spacers 110which are preferably spring loaded and two adjustable position spacers108 which are also preferably spring loaded. Plate 106 swivels around acentral pillar 104 such that plate 106 is parallel to the X Y planeshown in FIG. 1 e.

Reference is now made to FIGS. 1f and 1g which show an isometric viewslooking at the topside and bottom side of bracket 10 according to anaspect of the present invention. FIGS. 1f and 1g show the four mountingholes 102, two fixed positioned spacers 110, the two adjustable positionspacers 108, plate 106 and central pillar 104.

Reference is now made to FIGS. 2a and 2b which show a plan view 20 andside view 22 of bracket mount 10 attached to junction box 200 via fourmounting holes 102 according to an aspect of the present invention.FIGS. 2a and 2b show the two fixed positioned spacers 110, the twoadjustable position spacers 108, plate 106, central pillar 104, bracketmount 10 and junction box 200 along with cable glands 14, male socketconnectors 12 a and female socket connectors 12 b.

Reference is now made to FIGS. 3a and 3b which show an isometric view 30and isometric view of area 32 respectively according to an aspect of thepresent invention. FIG. 3a shows the photovoltaic side of two solarpanels 300 a and 300 b with bracket mount 10 (attached to junction box200) attached in between two solar panels 300 a and 300 b (shown by area32). FIG. 3b shows further details of the isometric view of area 32.With bracket mount 10 attached to junction box 200, bracket mount 10 andjunction box 200 are located on the non-photovoltaic side of solarpanels 300 a and 300 b. Central pillar 104 protrudes between solarpanels 300 a and 300 b with plate 106 twisted around central pillar 104so that plate 106 is in contact with the photovoltaic side of panels 300a and 300 b. The two fixed positioned spring loaded spacers 110 and thetwo adjustable spring loaded position spacers 108 (shown with a dottedline) allow bracket 10 (attached to junction box 200) to clamp ontopanels 300 a and 300 b. Through a gap between panels 300 a and 300 b canbe seen fixed positioned spacers 110 and a male socket connector 12 a.

Reference is now also made to FIG. 4, a flow diagram illustrating amethod according to features of the present invention for attachingjunction box 200 to one or more photovoltaic panels 300. A first side ofbracket 10 is attached (step 41) to junction box 200 and a second sideof bracket 10 is attached (step 41) to the non-photovoltaic side. Acentral fastener 104 is attached (step 43) at one end to bracket 10.Bracket 10 may be previously assembled with the fastener 104, and theinstaller only mounts the junction box 200 to bracket 10, and then mountbracket 10 to panel 300 Plate 106 is rotatably connected (step 45) tothe other end of the central fastener 104 and mounted on thephotovoltaic side of photovoltaic panel 300. One or more rotatablespacers 108 are connected on the non-photovoltaic side to the centralfastener. Bracket 10 may be attached to non-photovoltaic sides of twoadjacent photovoltaic panels 300 and central fastener 104 extendsbetween respective edges of two adjacent photovoltaic panels 300. Thetwo adjacent photovoltaic panels 300 may be electrically connectedwithin junction box 200. Alternatively, bracket 10 is attached tonon-photovoltaic sides of four adjacent photovoltaic panels 300, andcentral fastener 104 extends between respective corners of the fouradjacent photovoltaic panels 300. The four adjacent photovoltaic panels300 may be connected within junction box 200.

The definite articles “a”, “an” is used herein, such as “a bracket”, “ajunction box” have the meaning of “one or more” that is “one or morebrackets” or “one or junction boxes”.

Examples of various features/aspects/components/operations have beenprovided to facilitate understanding of the disclosed embodiments of thepresent invention. In addition, various preferences have been discussedto facilitate understanding of the disclosed embodiments of the presentinvention. It is to be understood that all examples and preferencesdisclosed herein are intended to be non-limiting.

Although selected embodiments of the present invention have been shownand described individually, it is to be understood that at least aspectsof the described embodiments may be combined. Also although selectedembodiments of the present invention have been shown and described, itis to be understood the present invention is not limited to thedescribed embodiments. Instead, it is to be appreciated that changes maybe made to these embodiments without departing from the principles andspirit of the invention, the scope of which is defined by the claims andthe equivalents thereof.

1-17. (canceled)
 18. An apparatus, comprising: a fastener configured toextend between at least two photovoltaic panels; a bracket connected tothe fastener, wherein the bracket is configured to attach to a junctionbox, wherein the junction box is configured to electrically connect theat least two photovoltaic panels; and wherein the fastener and thebracket are configured to clamp therebetween at least one of the atleast two photovoltaic panels.
 19. The apparatus of claim 18, furthercomprising an adjustable spacer configured to be mounted and adjustablein a space between the bracket and at least one of the at least twophotovoltaic panels.
 20. The apparatus of claim 19, wherein theadjustable spacer is rotatable around the fastener.
 21. The apparatus ofclaim 18, further comprising a fixed spacer configured to be mounted ina space between the bracket and at least one of the at least twophotovoltaic panels.
 22. The apparatus of claim 18, wherein the bracketis configured to attach to a non-photovoltaic side of at least one ofthe at least two photovoltaic panels.
 23. The apparatus of claim 18,further comprising a plate rotatably connected to the fastener.
 24. Adevice comprising: a bracket configured to attach to (1) a firstjunction box and (2) a first photovoltaic panel or a second photovoltaicpanel; and a fastener attached to said bracket, wherein the fastener andbracket are configured to suspend the first junction box from the firstphotovoltaic panel or the second photovoltaic panel by clamping thefirst photovoltaic panel or the second photovoltaic panel between thebracket and the fastener.
 25. The device of claim 24, wherein thebracket is further configured to attach to a third photovoltaic paneland a fourth photovoltaic panel.
 26. The device of claim 25, wherein thefastener and bracket are further configured to clamp the thirdphotovoltaic panel and the fourth photovoltaic panel between the bracketand the fastener.
 27. The device of claim 24, wherein the bracketcomprises mounting holes configured to attach of the bracket to thefirst junction box.
 28. The device of claim 24, wherein, the firstjunction box is attached, using the device, to the first photovoltaicpanel on a side thereof and the second photovoltaic panel has a secondjunction box attached, using the device, to a side thereof.
 29. Thedevice of claim 28, wherein the second junction box is operablyconnected to the first junction box.
 30. The device of claim 24, whereinthe first junction box includes a direct-current-to-direct-currentconverter or a direct-current-to-alternating-current converter.
 31. Amethod for mounting a first junction box to at least one of at least twophotovoltaic panels comprising: clamping the at least one of the atleast two photovoltaic panels between a bracket and a fastener extendingbetween front or back sides of the at least one of the at least twophotovoltaic panels, wherein the bracket is configured to mount at leastthe first junction box.
 32. The method of claim 31, further comprisingmounting a spacer between the first junction box and the at least one ofthe at least two photovoltaic panels.
 33. The method of claim 31,wherein the at least two photovoltaic panels include a firstphotovoltaic panel and a second photovoltaic panel, and wherein themethod further comprises electrically connecting the first junction boxto the first photovoltaic panel and electrically connecting a secondjunction box to the second photovoltaic panel, wherein the bracket isconfigured to mount the second junction box.
 34. The method of claim 33,further comprising electrically connecting the first junction box to thesecond junction box.
 35. The method of claim 33, further comprising:mounting the first junction box to the first photovoltaic panel byclamping the first photovoltaic panel between the bracket and thefastener; and mounting the second junction box to the secondphotovoltaic panel by clamping the second photovoltaic panel between ofthe bracket and a second fastener.
 36. The method of claim 33, furthercomprising electrically connecting the first junction box to the firstphotovoltaic panel and to the second photovoltaic panel.
 37. The methodof claim 31, wherein at least two photovoltaic panels are adjacent andelectrically connected within the first junction box.